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Manufacturing Cost Analysis of 10 Kw and 25 Kw Direct Hydrogen Polymer Electrolyte Membrane (Pem) Fuel Cell for Material Handling Applications

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Manufacturing Cost Analysis of 10 Kw and 25 Kw Direct Hydrogen Polymer Electrolyte Membrane (Pem) Fuel Cell for Material Handling Applications MANUFACTURING COST ANALYSIS OF 10 KW AND 25 KW DIRECT HYDROGEN POLYMER ELECTROLYTE MEMBRANE (PEM) FUEL CELL FOR MATERIAL HANDLING APPLICATIONS Prepared by: BATTELLE Battelle Memorial Institute 505 King Avenue Columbus, OH 43201 Prepared for: U.S. Department of Energy Golden Field Office Golden, CO DOE Contract No. DE-EE0005250 March 25, 2013 This report is a work prepared for the United States Government by Battelle. In no event shall either the United States Government or Battelle have any responsibility or liability for any consequences of any use, misuse, inability to use, or reliance upon the information contained herein, nor does either warrant or otherwise represent in any way the accuracy, adequacy, efficacy, or applicability of the contents hereof. Table of Contents 1 INTRODUCTION ................................................................................................................................ 1 2 APPROACH ......................................................................................................................................... 1 3 MARKET ANALYSIS ......................................................................................................................... 3 3.1 Market Summary ...................................................................................................................... 4 3.2 Technology Selection ............................................................................................................... 6 3.3 Conclusions............................................................................................................................ 11 4 SYSTEM SPECIFICATIONS ............................................................................................................ 12 4.1 General Description ............................................................................................................... 12 4.2 Electrical System .................................................................................................................... 15 4.3 Balance of Plant (BOP).......................................................................................................... 17 5 MANUFACTURING COST ASSUMPTIONS .................................................................................. 18 5.1 Stack Manufacturing Process and Cost Assumptions ............................................................ 18 5.2 Electrical System Cost Assumptions ..................................................................................... 23 5.3 Balance of Plant Cost Assumptions ....................................................................................... 26 5.4 System Assembly and Learning Curve Assumptions ............................................................ 31 5.5 Capital Cost Assumptions ...................................................................................................... 32 6 LIMITATIONS OF THE ANALYSIS ............................................................................................... 33 6.1 Manufacturing Costs .............................................................................................................. 33 6.2 Balance of Plant Hardware Costs........................................................................................... 34 7 COST ANALYSIS RESULTS ........................................................................................................... 34 7.1 10 kW Cost Analysis Results ................................................................................................. 34 7.2 25 kW Cost Analysis Results ................................................................................................. 36 8 SENSITIVITY ANALYSIS ................................................................................................................ 38 9 LIFECYCLE COST ANALYSIS OF FUEL CELLS ......................................................................... 41 10 CONCLUSIONS ................................................................................................................................. 43 10.1 System Cost Summary ........................................................................................................... 43 10.2 Results.................................................................................................................................... 48 Appendix A – Stack Manufacturing Process and Cost Assumptions ........................................................... 2 A.1 Bipolar Plate Manufacturing Process Documentation ........................................................................... 2 A.2 End Plate Manufacturing Process Documentation ................................................................................. 8 A.3 Gasket Manufacturing Process Documentation ................................................................................... 13 A.4 Membrane Electrode Assembly (MEA) Hot Processing Manufacturing Documentation ................... 18 A.5 Membrane/Catalyst Manufacturing Process Documentation ............................................................... 24 A.6 Cost Comparison to DTI 2010 ............................................................................................................. 36 A.7 Assembly Cost Learning Curve Calculations ...................................................................................... 39 iii List of Figures Figure 2-1. Battelle’s Cost Analysis Approach ........................................................................................ 2 Figure 3-1. Distribution of Class 4 & 5 Forklift Truck Power Ranges ..................................................... 8 Figure 3-2. CDPARRA-MHE-23: Average Daily Fuel Cell Operation Hours (by fleet) ......................... 9 Figure 3-3. Distribution of Class 7 Forklift Truck Power Range ........................................................... 11 Figure 4-1. PEM System Schematic for 10 kW and 25 kW MHE Applications .................................... 13 Figure 5-1. Fuel Cell Stack Manufacturing Process ............................................................................... 19 Figure 5-2. Distribution of Costs across Components for 10 kW Design. ............................................. 29 Figure 5-3. Distribution of Costs across Components for 25 kW Design. ............................................. 29 Figure 5-4. Variation in Balance of Plant Costs with Different Hydrogen Storage Systems ................. 31 Figure 7-1. Cost Breakdown of 10 kW Stack ......................................................................................... 35 Figure 7-2. 10 kW MHE PEM Fuel Cell BOP Hardware Cost Breakdown (i.e. No System Assembly) ............................................................................................................................ 35 Figure 7-3. 10 kW MHE PEM Fuel Cell BOP Hardware Cost Breakdown (i.e. No System Assembly) without Battery and Hydrogen Storage System ................................................. 36 Figure 7-4 Cost Breakdown of 25 kW Stack ......................................................................................... 37 Figure 7-5. 25 kW MHE PEM Fuel Cell BOP Hardware Cost Breakdown (i.e. No System Assembly) ............................................................................................................................ 38 Figure 7-6. 25 kW MHE PEM Fuel Cell BOP Hardware Cost Breakdown (i.e. No System Assembly) Without Battery and Hydrogen Storage System ................................................ 38 Figure 8-1. Sensitivity Analysis: 10 kW Stack Cost – 10,000 Production Volume ............................... 40 Figure 8-2. Sensitivity Analysis: 25 kW Stack Cost – 10,000 Production Volume ............................... 40 Figure 10-1. Distribution of Costs for 10 kW System (100 units/yr) ....................................................... 44 Figure 10-2. Distribution of Costs for 10 kW System (1,000 units/yr) .................................................... 45 Figure 10-3. Distribution of Costs for 10 kW System (10,000 units/yr) .................................................. 45 Figure 10-4. Distribution of Costs for 25 kW System (100 units/yr) ....................................................... 46 Figure 10-5. Distribution of Costs for 25 kW System (1,000 units/yr) .................................................... 47 Figure 10-6. Distribution of Costs for 25 kW System (10,000 units/yr) .................................................. 47 Figure A-1. Bipolar Plate Manufacturing Process ..................................................................................... 2 Figure A-2. End Plate Manufacturing Process .......................................................................................... 9 Figure A-3. DFM Analysis for 10 KW End Plate ................................................................................... 12 Figure A-4. DFM Analysis for 25 KW End Plate ................................................................................... 13 Figure A-5. Gasket Manufacturing Process ............................................................................................. 14 Figure A-6. MEA Hot Processing Manufacturing Process ...................................................................... 18 Figure A-7. Membrane / Catalyst Manufacturing Process ...................................................................... 26 List of Tables Table 3-1. System Operating Requirements
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